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  #1  
Old 21st October 2021
sportsterpaul's Avatar
sportsterpaul sportsterpaul is offline
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Sportster/Buell Model: XL1460C
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Sportster/Buell Model #2: XL1200R
Sportster/Buell Year #2: 2006
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Default Oil pressure switch

Developed a leak, originally thought it was a base gasket, traced it back to the switch which is located under the oil filter mount at the front of the engine. Difficult to get to with cramped quarters but I gave it a try. Note: regular sockets don’t work on this, the F.S.M. calls for use of an Oil Pressure Switch Socket #453000. The switch is actually round with indentations in it-creating the need for a “special socket”. I tried everything in my tool boxes even a faucet wrench.
”Coastie56”did find a you-tube video an Englishman had posted, he used a medium pair of channel locks from the left side of the bike. Tedious and quite time consuming as you get minimal rotation, stop and regrip then more of the same, about 15-20 minutes worth.
I visited my guy at the local Car Quest Auto Parts store and he had the special socket on hand, cost to me was $11.00. I believe these switches are used on many different vehicles. With the proper socket and a 6” extension fed up from below the old switch came out in about ten seconds, yea! Now I have another special tool as well.
Oh, the switch is part#26554-77B. I may be the only guy in history that needed to do this but it may help someone else down the road.
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Last edited by sportsterpaul; 22nd October 2021 at 02:10..
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  #2  
Old 22nd October 2021
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Done that. Tedious at best. I couldn't get the socket to work. But the channel locks are fine by me. PS620 is the AutoZone part number.

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Old 22nd October 2021
Andy56 Andy56 is offline
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In 2008 HD state tool HD 48386 oil pressure sending unit wrench.

In 2017 HD stopped advertising the tool in the section for the oil pressure switch and I cannot find any reference to a special tool in the manual.
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Old 22nd October 2021
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The socket I have was bought at AutoZone. I couldn't get it past the motor mount bolts IIRC. I wasn't aware of the HD tool.

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Old 22nd October 2021
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Sportster/Buell Model: XL1460C
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Default

Ed, my socket came from Car Quest part#LST 13200, but my saga continues- removing the switch from Orange was just the beginning and as easy as it was to remove it should have warned me what lay ahead with the install on Black Beauty. Decided just to work out on the driveway, what possibly could go wrong, right? Put my mat down and tools within reach, as was the replacement switch with pipe thread compound on its threads.Fed the switch socket into the gap and on up over the old switch, worked extension and ratchet up and into place and tried backing out the old switch. W.T.H.it just spins, cursing commences. Now’s when I justify my avatar......what now? Resort to the channel lock remedy, which did work but started out tediously until I noticed by hooking the curved channel lock jaw behind the switch then pulling quickly it spun nicely. A couple times and she dropped right out saving me a bunch of what was going to be very tedious labor, lesson learned and now shared. Sprayed the area down with brake clean then snuck the switch, housed in the socket into the gap and slid the ratchet extension up from below the cross member engaging the socket and popping the ratchet in place lined her up and tried install, and tried and tried. For some inexplicable reason my angle of attack was of by the proverbial R.C.H. No problem I’ll just slip a flex extension in between the socket and extension bar. Okay, now the flex ext. flops too much and I’m unable to line it up with the socket hole, damn. Pull everything out dig through my kitchen cupboard and locate a large rubber band wrapping it several times around the flex extension which stiffens it and allows me now to reinstall my fools and finally run the switch into the housing. But wait, this bad boy is going in way too stiff- so very much like a cross threaded issue. Back it out a little restart and runs in but very tight, by sight the alignment looks good but the whole area is restricted access and only a slight sight line from both sides. I decide to continue, I know a disaster waiting to happen. Switch snugs up so I reinstall the oil filter,(I had removed it hoping to gain more access), sprayed brake clean all over, wipe up all that I could reach put keys in ignition and fired her up, fingers crossed. Sigh of relief as no leakage anywhere, yea! Oil light came on with ignition and went out quickly. I should now be good to go.
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Old 22nd October 2021
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Default

Andy, it’s in the F.S.M. In the electrical section, try 7.32

Ed, my saga continued and I added to the post

F.W.I.W. the tool is a common one and can be found at most automotive parts stores. I believe the switch itself is common to many different vehicles and is easily found without going to a dealer.
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Old 4 Weeks Ago
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About 300 miles since the repair, all is good at this point. Absolutely no idea why the socket worked great on the first switch but spun on the second one? Q.C ?
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